Bandsaw blade - durable and highly efficient. WIKUS Band Saw Materials Band Saw Products

The band saw is used for sawing wood products, plywood, fiberboard and MDF. There are varieties of it that are able to dissolve logs onto boards. A professional band saw is most often used in large and medium-sized industries, where speed and volume of material processing are important. But recently it has gained popularity among home craftsmen.
The band saw can be used to cut flat workpieces of various thicknesses. Only unlike a jigsaw, both hands are free when working on this equipment, and a comfortable wide bed is offered for moving the workpiece. Most often, a band saw is used to cut workpieces of complex curved lines.

The principle of the band saw

On the vertical bed, two drum discs are fixed, transmitting the torque from the engine to the metal sawing band. In the sawing area on the bed there is a working table placed horizontally. On it there is a movement of workpieces and their sawing according to the principle of a jigsaw.

We prepare materials and tools

Materials:

Plywood 16-18 mm;
Bearings for drum shafts;
Metal studs with thread for shafts, diameter - 10-12 mm;
Sawing tape;
Insulating tape;
Bolts, nuts, screws, wood glue or PVA.

Instruments:

Jigsaw;
A circular saw;
Drill or drilling machine;
Emery for wood;
Clamps;
Roulette, pencil, sandpaper.

Making a band saw

Our machine will be almost entirely made of plywood. Therefore, for the base frame, we cut four identical strips of plywood on a circular or a jigsaw, as shown in the photo. It is advisable to take a larger thickness.

We cut out the grooves for the tensioner, the bed and the fastening of the drums with a jigsaw. For greater identity of holes and grooves, you need to fasten the parts with a clamp in pairs before sawing. As a result, we should have two pairs of different frames.

Now you need to glue the plywood with wood glue or PVA, and connect all parts of the base. For better crimping, you can squeeze the edges of the gluing with clamps.

We make a tensioner for the tape from a small wooden block or two spliced pieces of plywood. It should fit snugly into the groove as along the guides. We drown it with a wooden strip so that the tension screw passes through it, fixing it to the self-tapping screws.

The rest of the plywood will go to the drums. Having marked them out, we make a hole for the shafts, and then cut it out around the circumference with a jigsaw. Align and clean the edges of the plywood with emery on the wood. To prevent slipping of the tape, the author preferred to seal the ends of the drums with electrical tape.

We install bearings at the site of the shafts. Two of these will be on both sides of the stationary drum bed. The other two are located on the tensioner. We also mount a locking bolt to secure the tensioner from the back of the bed.

We fix both drums on the bed so that they can move freely on the shafts without clinging to the machine body. We tighten the saw band and adjust the tension with the tensioner, while fixing it with a stopper. Since the band saw is designed for vertical sawing, it is necessary to attach a lower platform to it from a wide board or a piece of plywood for stability. The sawing area also needs a work table on which the workpieces will move.

Is a cutting tool used for band saws. By its design, the band saw is a flexible steel band, tightly looped, with a row of teeth along one edge.

The band is mounted on two pulleys that are driven by the electric motor of the band saw.

With a band saw, you can make both straight and curved cuts. That is why the area of its use is very diverse and is not limited only to furniture production.

Types of band saws

Band saw blades can be divided into the following views:

toothed;
toothless;
electric spark principle of action.

Toothless Band Saws and electric spark saws the actions work in the same way as circular saws. The only difference is the purpose of the teeth.

When choosing a band saw for metal, you need to pay attention to the design features of the band saw machine.

The main purpose of a band saw for metal - This is the execution of angular, straight and curly cuts. If you need to cut at an angle, you will need to purchase special swivel jaws for this machine.

Saw band characteristics and properties

The main properties and characteristics of the saw are:

cutting height and width;
type of cutting blade;
electric motor power;
the total mass of the machine and the diameter of the pulleys.

up to 300mm - light;
from 420 to 500 mm - medium;
with a pulley diameter over 500 mm - heavy.

Lightweight band saws are equipped with an electric motor up to 2 kW, medium and heavy electric motor up to 4 kW.

Blade types

For sawing, special demands are placed on the band saw blade.

For cutting metals, bimetallic blades are used, consisting of two metals. The main part of which consists of a metal strip made of special spring steel, and the working part consists of tool steel with sharpened teeth.

The widespread use of cloths made of carbon steel. According to their heat treatment, the tape canvases can be divided into the following types:

with the same hardness across the entire width;
with flexible blade and hard teeth;
hardened blades across the entire width.

Blades with the same hardness across the entire width work well on medium-diameter pulleys. The Rockwell hardness of the canvases is 47 units.

Saws with flexible blade and hard teeth have a specific structure. Only the top half of the tooth will be hardened, leaving the saw blade flexible. The Rockwell saw body hardness is 31 units, the hardness of the teeth is 64 units.

Full-width saws with hardened blades are the most sought after. Their blade hardness according to Rockwell is 52 units, and the hardness of the teeth is 67 units.

Due to the high hardness of the teeth, the resistance to blunting is significantly increased, and the increased rigidity allows cutting at high speeds.

Sharpening band saws for wood

When cutting wood or metal, the band saw teeth may lose their original sharpness. That is why you need to sharpen an electric band saw.

Sharpening the saw band is as follows:

initial sharpening;
cleaning;
wiring;
final sharpening.

To restore the cutting qualities of the saw band teeth, use special sharpening machines.

As a result initial sharpening you will eliminate all cracks in the sinuses of the teeth, as well as restore the profile teeth in compliance with a certain symmetry to the rest.

When cleaning all metal filings remaining after sharpening are removed.

When wiring change angles.

When final sharpening correct the admitted symmetric distortions of the corners and sharpen the working edges of the teeth.

Sharpening saws with your own hands will require certain skills and abilities from you. Therefore, if you are not sure about the quality of your work, leave this matter to specialists.

Professional sharpening will restore the squareness of all cutting edges.

Band sawing machines are an indispensable tool in the production of parts with complex shapes. The specifics of the enterprise predetermine the configuration of the equipment, its operational characteristics and the choice of used consumables. The efficiency of work depends on the correct choice of the desired model and the economic feasibility of the application. To do this, you need to know the capabilities of the band saw equipment and the principles of work on it. The belt blades can be made of various grades of steel, have a certain pitch and set of teeth.

Application area

For each type of work, manufacturers try to offer a selection of products with clearly marked qualities. Bandsaw equipment is widely used in metalworking, woodworking, construction business. Cutting of plastic and composite materials is carried out. Ferrous and non-ferrous metals are processed. Bandsaws are universal. By replacing the brand of the blade, its pitch and cutting modes, on the same equipment, you can effectively produce parts from completely different materials. At the same time, high accuracy, minimum waste and high speed of operations are ensured.

Classification

The division into types of band saw tools is made according to several basic parameters. This is the purpose of the canvas. When choosing, it is taken into account which material the product is intended for:

Saws for wood. Sufficient wear resistance and quality of sharpening are important. The part after processing should have a smooth cut with a minimum tolerance for finishing operations. For woodworking operations, the blade is produced in a special version. The tooth pitch, belt width and strength characteristics of steel have been calculated. With a deterioration in performance, repair and sharpening is allowed.
Saws for metal. Depending on the strength of the material being processed, a model of a band saw blade with the required parameters is selected, such as the sufficiency of the strength of the cutting part, the length and pitch of the teeth.
Universal canvases. They are designed to work with materials of different structure and strength. One saw can work on both metal and wood. While there are obvious advantages, there are also significant disadvantages. Such canvases will play out for specialized products of a narrow focus. It is advisable to use such a band saw equipment only for a variety of work in workshops and small shops, where such a choice will be fully justified. Somewhat worse performance is offset by versatility. There is no need to readjust the band saw equipment and change the blade. Several versions are available with different types of cutting edges and tooth pitches, made from different grades of steel. By width, the blades are divided into standard sizes from 6 to 54 mm.

The quality of the cutting part is of no small importance. Depending on the material of manufacture, the canvases are classified as follows:

Cutting technology

The main advantage of working with a band saw is productivity and a number of operations unattainable when using circular machines and equipment with a reciprocating principle of action. The ability to change the motion vector during the cutting process makes it possible to process curved surfaces with high accuracy. A valuable quality in the joinery industry, where woodworking often requires complex parts to be completed. Tape blades are also effective when cutting profiles and pipes. In terms of the popularity of application, such equipment competes with other devices of this class. In the event of damage, repairs are possible to fully restore performance.

The cutting principle consists in the continuous movement of a cutting blade made of steel, welded into a ring in a special mechanism. This provides a number of advantages in operation. The clamping force is directed downwards, and the absence of a reverse stroke makes additional fixing of the part unnecessary in some operations. Often, when working on wood, the part is held in the hands, and the cut is carried out according to the marks. The main disadvantage of circular saws, for all their advantages, is the impossibility of making a curvilinear cut and the absence of its vertical line. The cut is always radial, repeating the angle and diameter of the disc. The tape is devoid of these shortcomings. The cut along the entire length and the edge is obtained strictly vertical, perpendicular to the plane of the material being processed. Cutting methods depend on the band saw model. Modern versions are equipped with the necessary additional equipment and accessories for automatic or semi-automatic operation.

Production technology

The main task in the manufacture of the tool is a high-quality joint when forming a loop from a workpiece.

The tape is delivered from the manufacturer in a coil in a whole piece. Then it is cut into pieces and welded to the finished product using a special machine. Ideally, after cleaning and sanding the joint, this area should not be visible. Production is demanding in all respects. The blade should not lose strength, the roughness of the belt should not exceed the permissible standards, and the shape and pitch of the teeth are preserved.

The choice of products with different lengths, thicknesses, and pitch of teeth is quite large. The production is trying to offer the maximum selection of canvases for the user with certain geometric and operational characteristics. When purchasing, it is necessary to carefully analyze the tables with the recommended saw parameters for specific types of work. The characteristics of the band saw on which the blade is placed are also of great importance. The belt speed and the feed of the processed material are the basic technical parameters, based on which the optimal saw models, tooth pitch and setting are determined.

Sooner or later, the tape loses its quality and needs to be replaced, but installing a new belt is not always cost-effective. Having a significant resource in terms of its strength characteristics, it is economically profitable to send a tool for repair. The band saw is freed from the saw, which, after certain operations, will be operational again. The main task is to restore the cutting ability of the blade. For this, the necessary procedures are determined:

Welding. It is used in case of violation of the integrity of the product, loss of part of the teeth or other serious damage. When welding, the steel grade and the joint are taken into account, the requirements for which are the same as in industrial production.
Cleaning. During operation, adhesion of melted particles of the processed material, scale and other foreign substances is possible. This makes cutting very difficult and degrades its quality. The decline in working qualities does not have the best effect on the main production. After cleaning, the blade is suitable for installation in a band saw. This type of repair is often carried out on site.
Sharpening. The cutting edge is repaired using an abrasive tool. In this case, the pitch of the teeth and their shape must remain the same. Disturbing the saw blade geometry will alter its performance.
Wiring. The necessary quality for the free movement of the belt in the material being processed. Under load during operation, the deviation of the teeth from the blade, set during production, is reduced. The saw starts to "bite" or it starts to deviate from the vector of motion to the side. Correct wiring will return the required performance.

All types of blades can be repaired, and simple models for wood, and bimetallic band saws for hard grades of steel. Tool remanufacturing improves key economic indicators, making production more profitable.

The productivity of a band saw directly depends on how correctly the band saw blade is chosen. There are many varieties of saw blades that differ:

material of manufacture;
the shape of the teeth;
sharpening them;
type of wiring.

The band saw blade for metal is made of monolithic carbon steel or bimetallic composition. Steel blades with tensile strength up to 80 MPa are intended for sawing non-ferrous metal, plastic, solid steel and cast iron blanks. They are well proven on cantilever and single column machines for industrial and semi-industrial applications.

On powerful two-column machines, in most cases, a bimetallic strip blade for metal is used. This type of saws has a complex design, the basis of which is a flexible and durable tape made of spring steel, on which teeth are soldered from tool steel of high-speed grade 1R2M10K8 (or other alloys with similar characteristics). They are characterized by high hardness, about 950 HV. The teeth are located in special sockets and are fixed by the method of electron beam soldering.

Bimetallic band saws are used for cutting cast iron, steel of all types, extra strong alloys. As a rule, they are used for working with solid workpieces; when cutting pipes and profiles, it is better to use ordinary steel saws.

If you choose the shape of the tooth and the setting correctly, then the carbide tape blades do an excellent job with all types of stainless steel.

The band saw blade has 1 to 32 teeth per linear inch. If the choice of a band requires an inconsistent tooth pitch, then the number is in the range from 0.75 / 1.25 to 10/14 per inch. The density of the teeth depends on their number, which stays in the cutting zone at the same time. Optimally 3-5.

The teeth of the cutting edge are not located in a straight line, but deviated to the sides from the plane of the main belt. The kind of this deviation is called the saw set. The teeth are alternately inclined to the right and left sides, which provides a wider than the thickness of the blade, the cutting line and prevents it from getting stuck in the material. The most commonly used wiring is of three types:

right, straight tooth and left;
right and left alternately;
wave-like setting with a variable angle of inclination of the tooth.

The first type is used when cutting packets of solid billets, pipes, profile rolled products. Wavy - for pipes, especially thin-walled, rolled small sizes with a small wall thickness. Standard right / left is almost universal, but works best when cutting soft materials such as copper, aluminum, non-ferrous alloys and plastic.

Tooth shape

Band saw blades are equipped with several standardized tooth shapes:

Tooth NORMAL (N) does not have a chamfer in front. The working edge is directed vertically upward. Used for cutting high carbon materials, thin wall pipes and rolled products.
HOOK (H) has a frontal slope of 10 0. Its purpose is to cut pipes with a thick wall and solid rods of any section made of alloy steel.
For non-ferrous alloys, high alloy steels, and difficult-to-cut metals, use a band saw blade equipped with RP tooth with a slope of the working edge and 16 0.
Tooth-shaped band blade MASTER differs in high versatility, in addition to the working front edge with an angle of 10 or 16 0, a longitudinal chamfer is ground, as a result of which the cut roughness is significantly reduced. These saw blades are used on all types of metal cutting machines.

The thickness of the material that it can process depends on the pitch of the saw. When cutting solid metal, choose a band saw blade with one pitch, pipes with another. The approximate parameters are shown in the tables below.

Cutting speed

Steel and bimetallic belt blades are designed for a given cutting speed. As a rule, it is indicated in special tables and has its own for each machine. If it was not possible to find the appropriate data for a specific machine or belt, then the optimal cutting speed can be determined experimentally, according to the chips obtained:

thin or dusty - feed is too slow or line speed of the belt is too high;
coarse shavings with a bluish-blue tint - high feed rate or low line speed;
curly spiral shavings of the same length - the operating mode is correct.

Each band saw blade is characterized by a certain performance and the ability to perform a certain number of cuts. For example, bimetallic 27x0.9 is characterized by productivity of 10-25 cm / min when cutting high-alloy alloys and 45-70 cm / min when working with structural steel grades. The average operating time of the saw blade is 150-170 operating hours.

Caring for your band saw

A band saw blade, like any other tool, requires proper storage and maintenance.

To extend the service life of the tape during interruptions in work, it should be removed from the machine and stored in a relaxed state. On the machine, the tension of the blade should not exceed 300 N / m, exceeding this indicator threatens with metal rupture or deformation.

During operation, the modes of coolant supply should be observed. Without lubrication and cooling, belt life is significantly reduced. When installing a new blade, you should "roll" it in idle mode for 10-15 minutes and only then perform several cuts in a mode with a load of up to 50% of the nominal.

Correct operation and durability of the band saw depends on the sharpening and setting performance. For these operations, there are special machines with different setting modes. When sharpening, in addition to the actual restoration of the sharpness of the teeth, the elimination of microcracks and defects arising in the sinuses is performed. Adjusting the stock removal height is also very important to maintain the strength of the web.

Sharpening is carried out without pressing the grinding wheel, in order to avoid annealing of the tape, which can occur even with the correct settings for the type of tooth and its pitch.

In the conditions of small-scale production, only metal band saws can cope with the tasks of cutting a variety of rolled products. Therefore, they are an indispensable attribute of many procurement industries. Today, we will dwell on the parameters of band saws, talk about the device and manufacturers.

Production tasks solved with band saws for metal

This equipment is usually characterized by a straight, narrow endless saw that moves in a circular path. The orientation of the saw blade for metal cutting can be vertical or horizontal. The cutting action is achieved due to the continuous movement of the closed saw blade along the arc, while simultaneously pressing the workpiece against the blade.

The device of a band saw for metal provides the ability to quickly change the shape and size of the final products, taking into account the strength characteristics of the workpiece material. With a large range of cut metal products, band saws are almost ideal equipment.

Unlike force or heat, due to which friction saws or sheet shears with an inclined knife cut metal, band saws perform a dynamic cut, the parameters of which can be easily and quickly reconfigured. This reduces wasted time.

Most often, metal band saws are used for:

Separation of metal along a complex contour with an optional clean cut surface, since the joints will subsequently be welded into a specific structure. In particular, cutting along a parabola, ellipse and similar shapes is successfully performed.
Straight and angular cuts on metal rods, pipes, profile rolled products, both tubular and solid cross-section.
Separation of workpieces made of metals and alloys with different indicators of strength, hardness and elasticity.

Thus, in terms of the ratio of production capabilities and the price of devices for mechanical cutting of metal, modern band saws have an advantage over less universal circular saws. Tool life is ensured by continuous supply of coolant to the machining zone.

Classification

Modern metal band saws differ:

The direction of movement of the belt - it can be in the vertical or horizontal direction.
Drive power - distinguish between compact machines with a power of up to 2000 ... 2500 W, and stationary, with a power of over 2500 W.
The speed of movement of the saw blade (it can be constant, which is practically not used in modern machines), or variable from 10 to 100 m / s.
The design of the saw blade itself, in particular, its material (it can be ordinary tool steel, high-speed steel, bimetal, hard alloy), as well as the pitch frequency of the teeth along the length of the blade (30 ... 80 m -1). The width of the saw blade also varies. For especially powerful models that perform, in addition to cutting itself, also cutting the end of the blank of the canvas can be double-sided.
The design of the band saw machine, which can have one or two columns.
The degree of automation of the metal cutting process. On a metal band saw equipped with a CNC, the speed of movement of the saw blade is controlled by an automatic device, which is adjusted depending on the material to be cut and its hardness.

The principle of operation of a band saw for metal is as follows. The working body of the saw is a flat flexible blade with teeth, which is welded into a continuous belt. This belt is put on two pulleys, one of which is driven. When the drive is turned on, the blade begins to move, and cut metal with its teeth. The material to be cut is constantly fed into the cutting zone at a certain speed, providing the necessary pressing force of the workpiece to the saw blade teeth.

The device of band saws for metal

It is determined by the purpose and layout of the machine. Consider the options most often offered by manufacturers.

Indiamart two-column semi-automatic band saw... Its feature is hydraulic blade tension and hydraulic clamping, which is equipped with a hydromechanical sensor. The speed of movement of the saw blade can be varied over a wide range, since it is driven by an AC motor with a variator. The blade is of high quality, which ensures the execution of cutting and trimming operations. The use of such a band saw is effective in various sectors of economic activity: from the automotive industry to the production of building metal structures.

Fully automated two-column band saw from Irlen-Engineering (Russia-China)... A feature of this machine is a widely variable speed of workpiece separation, good blade tension, excellent motion ability, a capacious hydraulic reservoir, as well as the ability to use when cutting metal with different strengths.

Vertical single-column band saws from the Czech company Proma... The peculiarity of such equipment is convenient access to the workpiece and the tool from three sides, high cutting accuracy, high quality of the welded joint of the saw blade parts. The machine is of semi-stationary type and can be easily moved from place to place.

Band saws for metal of the jet series (Taiwan). The machine implements the classic concept of a straight cut, therefore such equipment is often referred to as mechanical hacksaws. The design of such machines includes an oscillating frame and a crank mechanism, which provides a reciprocating movement of the saw blade. In terms of productivity, such machines are inferior to band saw equipment with a continuous belt.

Band saws from Enkor (Russia)... Domestic manufacturers of the equipment in question with conventional control are represented by machines of the Corvette model range, which also belong to the class of mechanical hacksaws for metal. The machines are equipped with the necessary control and measuring devices, allow you to optimize the cutting speed, and are equipped with highly resistant saw blades.

The obvious advantages of band saws for metal are the efficiency of changing the technological parameters of cutting, compactness, the ability to customize the tool for cutting various metals. The price of the equipment is determined by its capacity and functionality. It is:

For saws with manual material feed - from 16 thousand to 50 thousand rubles;
For semi-automatic saws - from 85 thousand to 280 thousand rubles;
For automatic metal saws with CNC - from 600 thousand to 1.3 million rubles.